Removing and installing turbocharger - vehicles with engine code letters ATL, BHC — AUDI

🧭 Before you start

Remove the catalytic converter, heat shields and charge air connections underneath, then the bonnet, wipers, cowl grille, fresh air duct, air pipe, flap motor, EGR cooler and intake manifold above. Disconnect the oil supply line, remove the turbo support and pendulum support bolts, undo the manifold nuts and lift the turbo out to the left. Refit with new gaskets and self-locking nuts, oil-primed, then check oil level and idle before load.

Fits: Audi A2 (8Z)

• Special tools named: 3094, puller
• Renewed: charge air cooler, gaskets

Don't miss

• After mechanical turbo damage, check air cleaner housing, filter and hoses for debris before fitting the new one.
• Clamp the EGR cooler coolant hoses with hose clamps 3094 rather than draining.
• Renew gaskets, seals and self-locking nuts; charge air system must be leak-free.
• Fill the turbocharger with engine oil at the supply connection before fitting the line.
• Idle for approx. 1 minute after starting; don't rev immediately.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ If the turbocharger has suffered mechanical damage (e.g. damaged compressor wheel), it is not sufficient merely to fit a new turbocharger. The following work must be performed in order to avoid further damage:Check air cleaner housing, air filter element and air hoses for dirt and foreign particles.Check the entire charge air system (including the charge air cooler) for foreign matter.If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew charge air cooler if necessary. — Remove front right wheel.
2. Remove catalytic converter .
3. Unbolt heat shield for drive shaft (left-side) (arrows).
4. Detach vacuum hose (1) from vacuum unit for charge pressure control and move it clear.
5. Unscrew bolts (2) and detach air pipe from turbocharger. [Note: Air pipe remains in installation position.]

6. Detach air hose (3) from turbocharger.
7. Remove nuts (1). [Note: Shown in illustration with engine removed.The bolts (2 and 3) are removed at a later stage.]
8. Remove heat shield for turbocharger (arrows).
9. Remove bonnet .
10. If fitted, unclip bracket (1).
11. Take off engine cover panel (arrows).
12. Remove noise insulation beneath cover.
13. Lever off caps (3 and 4) on two-piece windscreen wiper arm with a screwdriver.
14. Slacken nuts on two-piece windscreen wiper arm a few turns.
15. Release arms (1 and 2) one after the other by tilting them slightly on the wiper shafts.
16. Remove nuts completely and take off two-piece windscreen wiper arm. [Note: Use puller (commercially available) to remove wiper arm if necessary.]
17. Disconnect washer fluid hose (3).
18. If fitted, unplug electrical connectors (4 and 5) for heated washer jets.
19. Open hose clip (6) using hose clip pliersV.A.G 1921 and detach water drain hose from cowl panel grille.
20. Pull off rubber seal (1) on cowl panel grille.
21. Disconnect cowl panel grille (2).
22. Unscrew nuts and bolts (arrows).
23. Pull fresh air duct forwards and remove by turning it to right side of vehicle.
24. Remove air hose (3) from intake manifold flap motor V157 by lifting retaining clip (2) slightly.
25. Disconnect vacuum hose (1) at mechanical exhaust gas recirculation valve.
26. Detach air intake hose (1) at air mass meter G70.
27. Unplug electrical connector (3) at air mass meter G70.
28. Remove nut (2).
29. Disconnect crankcase breather hose (4) at cylinder head cover.
30. Pull air pipe out slightly together with air mass meter G70.
31. Detach electrical connector (arrow) at heater element for crankcase breather N79.
32. Remove air pipe.
33. Detach electrical connector (arrow) at intake manifold flap motor V157.
34. Remove bolts (1 … 3) and take out intake manifold flap motor V157.
35. Clamp off coolant hoses going to exhaust gas recirculation cooler using hose clamps 3094.
36. Detach coolant hoses at exhaust gas recirculation cooler.
37. Remove bolts (2 and 3) and detach exhaust gas recirculation cooler. [Note: Disregard (item 1).]
38. Unscrew bolts (arrows) and remove intake manifold.
39. Detach oil supply line (2) going to turbocharger at oil filter bracket.
40. Remove bracket for oil supply line (3). [Note: Disregard (item 1).]
41. Slacken bolt (1) approx. 3 turns.
42. Remove nut (2).
43. Unbolt oil supply line (3) from turbocharger and move clear to one side.
44. Unbolt bracket for air pipe from sump (arrows).
45. Remove bolts (1 and 2) and detach support for turbocharger.
46. Unbolt oil supply line (3) at cylinder block.
47. Remove bottom nuts (arrows 2).
48. Unscrew bolts (1) for pendulum support. [Note: Disregard (items 2 and 3).]
49. Remove top nuts (arrows 1).
50. Lift out turbocharger towards left. [Note: Renew gaskets, seals and self-locking nuts.Fill turbocharger with engine oil at connection for oil supply line.Charge air system must be free of leaks.Hose connections and hoses for charge air system must be free of oil and grease before assembly.Secure all hose connections with the correct type of hose clips (same as original equipment) Parts catalogue.]
51. Install intake manifold 23.
52. Install air pipes/hoses with plug-in connectors .
53. Install windscreen wiper arm 92.
54. Check oil level . [Note: After installing turbocharger, allow engine to idle for approx. 1 minute and do not rev up immediately to ensure turbocharger is supplied with oil.]

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